Full definition
A condition-based maintenance strategy that uses real-time monitoring and analysis of equipment operating parameters (vibration, temperature, oil condition, current, ultrasound, etc.) to detect the onset of degradation and predict when failure will occur, allowing maintenance to be scheduled at the optimal time — late enough to extract maximum useful life from the component, but early enough to prevent unplanned failure. Core technologies: vibration analysis (bearing and gear defects, imbalance, misalignment), infrared thermography (electrical connections, insulation, bearing temperature), oil analysis (wear particles, contamination, oil degradation), ultrasonic testing (leak detection, bearing lubrication assessment, electrical discharge), motor current analysis (rotor bar and stator faults), and online monitoring systems (continuous data from sensors on critical equipment). Per ISO 13374 (condition monitoring), ISO 17359 (condition monitoring guidelines), and ISO 55000 (asset management). ROI: typical PdM programs deliver 10:1 return on investment through: 25-50% reduction in maintenance costs, 70-90% reduction in unplanned downtime, 35-60% extension of equipment life, and 20-30% reduction in spare parts inventory. PdM is the foundation of Industry 4.0 and IIoT-enabled maintenance.